Don't cut your bump stops down as they're correct, I only do this if lowering springs are fitted as they will sit already compressed on the pads, they won't be causing the front to feel 'crashy'. If you don't believe me take them out & go for a test drive....other than the rear tyres might rub in bumpy corners the front will feel the same.
Normally worn front shocks cause this 'crashy' feeling. How new/old are the Konis? Koni Sports on the softest setting are meant to be similar/same as std front shocks......& yes I have currently got cars with both set ups but not Konis with std springs at the moment...I have had though. I've even got one with front Koni Sports & Monroe rears but that's on Eibachs. I've got & had many with the rear Powerflexed & that won't affect the front....you hardly notice any difference over std, IMO.
Current stock: Alfa Gtvs Spiders - CG Trading, Brighton, West Sussex
Has anyone checked the front top mounts? If they're new or good then I'd be tempted to fit new std front shocks.
I've said/posted many times that, unless for track use, then good/new std suspension is the best....especially for everyday driving on our 'normal/bad' roads.
Top mounts are new, as are the shocks.
Thanks for the input and I understand where you're coming from. I do think the Koni shocks are fine and I understand they're hard ride. That I get and am familiar with. Not confusing the issue. What I have is a definite heavy clunk on the wheel outers, mostly the left but sometimes the right. Very different to normal thumpy, hard riding suspension.
Here's mine. I presume from the photo your car is off the ground.
Thanks for the pic bro, yes, mine is from underneath with the wheels attached.
Don't mean to sound harsh; but if you were looking for a balance of ride (comfort) and handling then you picked the wrong front shocks. Koni Sports are HARD even on the softest setting. They are essentially track shocks and thus were certainly not designed for comfort and are likely the cause of the 'jarring' feeling you are getting from the front.
I would almost guarantee that you are confusing the 'jarring' ride from the front of the car as bottoming out, when its probably because the Koni's are so stiff that you feel like you are driving with rocks for suspension. Many users on this very forum have found the Sports to be far too hard (as Alfa_Andy himself has highlighted) and perhaps a different choice of front shock would fix your issues.
In regards to the back, you powerflexed the rear end. Powerflexing is well known to cause a slightly firmer/harsher ride (I would know) and then pair that with an all new suspension setup that has replaced a 10+ year old system, its going to be notably harsher.
Just to clarify. I would say the bump stops have absolutely nothing to do with the harsh ride you are experiencing. I think you just chose the wrong parts for what you wanted. You have chosen parts for a performance setup (ie, Koni Sports) and they are completely the wrong choice if you want a comfortable ride.
Short of swapping the front shocks for an OEM or 'softer' setup there isn't really anything you can do to change it imo
Thanks for the input but I think I can discern what hard riding shocks are like, this I understand. But over some potholes or heavy bumps it feels something is clunking ... just the once, heavy and distinct from a hard ride.
That's the front ... I'm reading a little wider and might have to work out whether it is the worn anti-roll bar bushes which I'm pretty sure are worn or to see if it's something to do with the steering rack or rack ends/tie rods.
The rear's not as much of an issue .. more jiggly over low speeds but settles in at speed.
As mentioned the ride's fine and I'm happy with the compromise. I'm not expecting a Citroen DS, I know what's possible. I've gone from tired original shocks with H&R springs and am happy with the choices I've made but whilst there's been improvement I'm looking to iron out the kinks .
I'm asking these question prior to replacing the rear roll bar and all bushes associated with the front and rear roll bars. Seriously thinking about the Alfaholics kit. Just trying to work out if ...
a) something was fitted incorrectly
b) the front roll bar bushes are causing the clunk/smash (could well be)
c) perhaps the sound is something related to steering rack or ends?
I've accepted input here that the bump stops are as they should be.
Much of the underpinnings will have to be unbolted for fitting bushes/roll bars and I'm hoping to use that time to sort out what may be the issue and double check whether everything is bolted up properly and working as it should be. Im not far off ... that's why it's so frustrating